System and method for mounting photovoltaic modules

ABSTRACT

A photovoltaic system includes a plurality of rectangular-shaped photovoltaic modules and a plurality of separate and spaced-apart support members supporting and orienting the photovoltaic modules in an array on the support surface without penetrating the support surface. The support members are formed of plastic and each of the photovoltaic modules is supported by at least four of the support members. Each of the support members is secured to and supports at least one of the photovoltaic modules but is not directly secured to any of the other support members. Thus the support modules can be utilized to support a wide variety of different sizes of photovoltaic modules. A wind shield is located at the rearward most support members. The wind shield is spaced a distance from the rearward photovoltaic modules and shaped to deflect wind up and over the array of photovoltaic modules.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of U.S. Provisional PatentApplication No. 61/447,883 filed on Mar. 1, 2011, the disclosure ofwhich is expressly incorporated herein in its entirety by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable

PARTIES TO A JOINT RESEARCH AGREEMENT

Not Applicable

REFERENCE TO APPENDIX

Not Applicable

FIELD OF THE INVENTION

The field of the present invention generally relates to mounting systemsand methods and, more particularly, to systems and methods for mountingphotovoltaic modules or panels on support surfaces such as, for example,building rooftops, the ground, or the like.

BACKGROUND OF THE INVENTION

A photovoltaic (PV) panel, often referred to as a solar panel or PVmodule, is a packaged interconnected assembly of solar cells also knownas PV cells. The PV module is typically used as a component of a largerPV system to generate and supply electricity in commercial andresidential applications. Because a single PV module can only produce alimited amount of power, most installations contain several PV modulesto form a PV array. The PV array is often mounted on a building rooftopor the ground with each of the PV modules in a fixed position facinggenerally south.

There are many mounting systems for securing PV modules to rooftops thatadequately withstand wind loads. However, these prior mounting systemsare not environmentally friendly, are relatively expensive to produce,time consuming to install, custom fabricated to each type or brand of PVmodule, and/or can damage the rooftop by penetrating a roof membrane.Accordingly, there is a need in the art for improved mounting systemsfor PV modules in rooftop applications.

SUMMARY OF THE INVENTION

Disclosed are mounting systems and methods that overcome at least one ofthe disadvantages of the prior art described above. Disclosed is amounting system for photovoltaic modules comprising, in combination, aplurality of separate support members supporting and orienting thephotovoltaic modules in an array. Each of the photovoltaic modules issupported by at least four of the support members. Each of the supportmembers is secured to at least one of the photovoltaic modules but notdirectly secured to any of the other support members.

Also disclosed is a photovoltaic system mounted on a support surface,where the system comprises, in combination, a plurality ofrectangular-shaped photovoltaic modules and a plurality of separate andspaced-apart support members supporting and orienting the photovoltaicmodules in an array on the support surface without penetrating thesupport surface. Each of the photovoltaic modules is supported by atleast four of the support members. Each of the support members issecured to and supports at least one of the photovoltaic modules but isnot directly secured to any of the other support members.

Also disclosed is a photovoltaic system comprising, in combination, aplurality of rectangular-shaped photovoltaic modules and a plurality ofseparate and spaced-apart support members supporting and orienting thephotovoltaic modules in an array. Each of the photovoltaic modules issupported by at least four of the support members. The system furthercomprises a wind shield at rearward most ones of the support membersthat is spaced a distance from the rearward most ones of thephotovoltaic modules and shaped to deflect wind up and over the array ofphotovoltaic modules rather than under the photovoltaic modules toreduce wind load.

From the foregoing disclosure and the following more detaileddescription of various preferred embodiments it will be apparent tothose skilled in the art that the present invention provides asignificant advance in the technology and art of mounting systems.Particularly significant in this regard is the potential the inventionaffords for a device that is universal, environmentally friendly, andrelatively inexpensive to produce and is easy to use. Additionalfeatures and advantages of various preferred embodiments will be betterunderstood in view of the detailed description provided below.

BRIEF DESCRIPTION OF THE DRAWINGS

These and further features of the present invention will be apparentwith reference to the following description and drawing, wherein:

FIG. 1 is a perspective view of an array of photovoltaic (PV) modulesutilizing a mounting system according to the present invention, whereineach of the PV modules is supported in a landscape orientation.

FIG. 2 is an enlarged perspective view of a portion of FIG. 1, showingsupport members of the mounting system.

FIG. 3 is a top/rear perspective view of one of the support members ofFIGS. 1 and 2.

FIG. 4 is a top/front perspective view of the support member of FIG. 3.

FIG. 5 is a bottom perspective view of the support member of FIGS. 3 and4.

FIG. 6 is rear elevational view of the support member of FIGS. 3 to 5.

FIG. 7 is another perspective view of an alternative version of thearray of PV modules shown in FIG. 1 but wherein the PV modules aresecured in a different orientation.

FIG. 8 is a perspective view of an array according to a secondembodiment of the present invention.

FIG. 9 is a perspective view of an array according to a third embodimentof the present invention.

FIG. 10 is a side elevational view of the array of FIG. 9.

FIG. 11 is a perspective view of a support member of the array of FIGS.9 and 10;

FIG. 12 is a fragmented cross sectional view showing an attachmentsystem for securing the PV Modules of the array of FIGS. 9 and 10.

FIG. 12A is a fragmented cross sectional view similar to FIG. 12 butshowing an alternative attachment system.

FIG. 13 is another perspective view of an alternative version of thearray of PV modules shown in FIGS. 9 to 11 but wherein the PV modulesare secured in a different orientation.

It should be understood that the appended drawings are not necessarilyto scale, presenting a somewhat simplified representation of variouspreferred features illustrative of the basic principles of theinvention. The specific design features of the mounting systems asdisclosed herein, including, for example, specific dimensions and shapesof the various components will be determined in part by the particularintended application and use environment. Certain features of theillustrated embodiments have been enlarged or distorted relative toothers to facilitate visualization and clear understanding. Inparticular, thin features may be thickened, for example, for clarity orillustration. All references to direction and position, unless otherwiseindicated, refer to the orientation of the mounting systems illustratedin the drawings. In general, up or upward refers to an upward directionwithin the plane of the paper in FIG. 6 and down or downward refers to adownward direction within the plane of the paper in FIG. 6. In general,front or forward refers to a direction towards the south and towards theleft within the plane of the paper in FIG. 1 and rear or rearward refersto a direction towards the north and towards the right within the planeof the paper in FIG. 1.

DETAILED DESCRIPTION OF CERTAIN PREFERRED EMBODIMENTS

It will be apparent to those skilled in the art, that is, to those whohave knowledge or experience in this area of technology, that many usesand design variations are possible for the improved mounting systems andmethods disclosed herein. The following detailed discussion of variousalternative and preferred embodiments will illustrate the generalprinciples of the invention with regard to the specific application ofrooftop mounted photovoltaic (PV) modules that are in the form ofrectangular-shaped panels. Other embodiments suitable for otherapplications will be apparent to those skilled in the art given thebenefit of this disclosure such as for example, ground mounted PVmodules and/or PV modules having differ shapes.

FIGS. 1 and 2 illustrate a photovoltaic system 10 according to thepresent invention. The illustrated photovoltaic system or array 10includes an array of solar panels or PV modules 12 mounted to asubstantially flat support surface 14 (pitch range of about 0 degrees toabout 5 degrees) in the form of a building rooftop 14 by a mountingsystem or assembly 16 according to the present invention. Theillustrated mounting system 16 includes a plurality of support members18 that rest on the support surface 14 and support and orient the PVmodules 12 above the support surface 14 and a plurality of ballasts 20in the form of ballast blocks that weight the support members 18 to thesupport surface 14 to maintain the position of the support members 18 onthe support surface 14. The illustrated PV array 10 has each of therectangular shaped PV modules 12 oriented in a portrait orientation,that is, with the longest axis of the PV modules 12 extending in aforward-rearward direction which is typically the south-north direction.It is noted, however, that the PV modules 12 can alternatively beoriented by the support members 18 in a landscape orientation, that is,with the longest axis of the PV modules 12 extending in a lateral orside-to-side direction which is typically the east-west direction (seeFIG. 7). In either the portrait or landscape orientations, theillustrated PV modules 12 are supported in an inclined position suchthat the forward end of each PV module 12 is positioned lower than itsrearward end so that typically the southern end is positioned lower thanthe northern end.

Each illustrated PV module 12 is supported by a plurality of the supportmembers 18. At least three of the support members 18 must be utilizedfor each of the PV modules 12 in order to establish a desired plane forthe PV modules 12. For the illustrated rectangular-shaped PV modules 12,at least four of the support members 18 are preferably utilized tosupport each of the PV modules 12 so that they can be positioned at ornear each corner of the rectangular-shaped PV modules 12. Each supportmember 18 supports at least one of the PV modules 12 but some of theillustrated support members 18 support more than one of the PV modules12. The illustrated PV modules 12 are secured to the support members 18(as described in more detail hereinafter) but each the support members18 is not directly secured to any of the other support members 18. It isnoted that while there is not a direct structural connection between thesupport members 18, the support members 18 are indirectly connected bythe PV modules 12 in a structural manner. That is, they are connected ina load carrying manner. It is noted that non-load bearing componentssuch as wind shields and the like can also be supported by the supportmembers 18 as discussed in more detail hereinafter. Thus, the supportmembers 18 are only structurally connected to one another through the PVmodules 12. Securing the support members 18 at or near the corners of PVmodules 12, and not directly connected to one another, allows themounting system 16 to be used with PV modules 12 of any width and lengthwithout requiring customization or modification to the support members18 or the PV modules 12. Thus a common support member 18 can be used inmany applications to mount many different models of PV modules 12. Also,the illustrated support members 18 are not fastened to the supportsurface 14 and simply rest on the support surface 14 as they areweighted in place by the ballast 20. Therefore the support members 18 donot penetrate the roof membrane of the support surface 14.

The illustrated mounting system 16 has the flexibility to be configuredto add resistance to wind loads at most installation sites. To furtherresist winds from the north which create the greatest need for ballastweight, one or more of the support members 18 can be placed in betweenthe support members 18 at the corners of the PV module 12 to addadditional ballast 20 and block wind from blowing underneath the PVmodule to create uplift. The additional support member also creates theability for ballast 20 in the form of a concrete block to be placed onits side and straddling two of the support members 18 to further createa wind barrier which prevents wind from blowing underneath the PV module12 to create uplift. The illustrated PV array 10 shows that supportmembers and straddling ballast 20 can be utilized to fully block therearward end of the PV array 10.

As shown in FIGS. 3 to 6, each of the illustrated support members 18 canbe quickly and removably attached to the PV module 12 without toolsusing an attachment system 21. The illustrated attachment system 21 isin the form of pivoting hooks 22. In the illustrated embodiment, up tofour pivoting hooks 22 can be secured at the forward or end and therearward end of the support member 18. The illustrated hooks 22 areadapted to engage and secure a lower flange 24 of the PV module 12. Bothends of the illustrated support member 18 are provided with a pair oflaterally spaced-apart upper holes 26 on each side of the support membercenterline 28 so that the hooks 22 can be located to engage PV moduleflanges 24 in both directions and having a variety of different widthsso that customization of the flange 24, hook 22, or support member 18 isnot required. Both ends of the illustrated support member 18 are alsoprovided with a pair of laterally spaced apart lower holes 30 on eachside of the support member centerline 28 for attachment of the hooks 22.More than two holes 26, 30 can be utilized if it is desired toaccommodate a wider variety of widths for the PV module lower flange 24.It is noted that any other suitable quantity and/or locations for theopenings 26, 28 can be utilized depending on how much flexibility inpositioning the hooks 22 is desired.

To secure the PV module 12 to the illustrated support member 18, thehook 22 is first attached to the support member 18 by inserting a firstremovable fastener 32 through an upper hole 34 of the hook 22 and intoone of the upper holes 26 in the support member 18 so that the hook 22is pivotably secured to the support member 18. That is, the hook 22 ispivotable relative to the support member 18 about the rivet 26. Theillustrated fastener 32 is a plastic push rivet. Suitable plastic pushrivets include TR and TRM rivets available from Richco Inc. of MortonGrove, Ill. It is noted that any other suitable fastener 32 canalternatively be utilized in place of the illustrated push rivets 32.With the hook 22 pivotably attached to the support member 18, the PVmodule 12 is placed onto the support member 18 and the PV module 12 issecured to the support member 18 by pivoting the hook 22 about the rivet(clockwise in FIG. 6) until the hook 22 is vertical and its hook portion36 is above and pressing down on the lower flange 24 of the PV module12. A second removable fastener 23 in the form of a plastic push rivetis inserted through a lower hole 38 of the hook 22 and into one of thelower holes 30 in the support member 18 so that the hook 22 is no longerpivotable relative to the support member 18. The illustrated attachmentsystem is low cost, universal, quick, easy, and robust. It is notedhowever, that any other suitable attachment system 21 can alternativelybe utilized to secure the PV modules 12 to the support members 18 ifdesired. For example, one alternative to the illustrated attachmentsystem 21 is to replace the push rivet 32 with a snap-in feature orfeatures integrally molded into the hook 22 that snaps into the upperholes 26 and/or locks into the lower holes 30 the hook 22 is beingpivoted into place. Also for example, another alternative to theillustrated attachment system 21 is to replace the hook 22 with a slidemechanism that slides across the top of the support member 18 after thePV module 12 is in place to trap the PV module's lower flange 24. Theslider of the slide mechanism could be held in place by snap-infeatures, fasteners, or the like.

The illustrated support member 18 is designed to be entirely comprisedof plastic and can be manufactured by thermoforming by using chamfers,gussets, large radii, and large draft angles. A suitable plastic is HighMolecular Weight Polyethylene (HMWPE) with UV inhibitor. It is notedhowever, that the support member 18 can alternatively comprise othermaterials and/or can be manufactured by other methods such as, forexample, injection molding or the like. Plastic enables desired complexshapes to be produced at relatively low cost and has other advantagesover prior art products made of aluminum, galvanized metal, andstainless steel materials. For example, plastic is rustproof, can bemade with 100% recycled materials and is 100% recyclable, does notrequire electrical grounding, and is harmless on the roof membrane, andis low cost.

The illustrated support member 18 is formed of thin walls and includes abottom wall 40 surrounded by hollow forward, rearward and side walls 42,44, 46 to form a central upward facing cavity 48. The cavity 48 is sizedand shaped for receiving the ballast as described in more detailhereinafter. The illustrated support member 18 includes an outerperipheral flange 50 that has an upturned outer edge or lip that isstepped slightly above the support surface 14 to prevent the edge fromdamaging the support surface 14 particularly when it is a thin roofmembrane. These upturned edges also add strength to flange 50. Theillustrated support member 18 utilizes built-in ribs 52 and a variablewall thickness to enable the support member 18 to adequately support thePV modules 12, and other loads such as large snow loads, with thin wallsand low cost commodity plastics. The hollow shape and large draft anglesallow for the illustrated support members 18 to be nested together whenstacked to lower shipping and handling costs.

The illustrated hollow forward wall 42 forms a first or forward supportsurface 54 at its top and the hollow rearward wall 44 forms a second orrearward support surface 56 at its top. The first support surface 54 issized and shaped to support the rearward ends of the PV modules 12. Thesecond support surface 56 is sized and shaped to support the forwardends of the PV modules 12. The first support surface 54 is located at aheight greater than a height of the second support surface 56 so thatthe PV modules 12 resting thereon are inclined. The difference in heightas well as the length of the PV module 12 determines the angle ofinclination of the PV module 12. The tilt angle is preferably within therange of 10 degrees to 12 degrees depending on the dimension of the PVmodule 12. The illustrated first and second support surfaces 54, 56 areeach inclined in the same direction (downward in a forward direction) toaccount for the inclination of the PV modules 12. The illustratedsupport member 18 is sized and shaped to automatically align the PVmodules 12 relative to one another when supported on the supportsurfaces 54, 56. The illustrated support member 18 includes variousfeatures to align the PV modules 12 in both the east/west direction(that is, the lateral direction) and the north/south direction (that is,the rearward/forward direction). By using these features to trap orprevent movement the PV module 12 relative to the support member 18 inall directions but up and the support surfaces 54, 56 prevent downwardmovement of the PV module 12, the attachment system 21 only needs tokeep the PV module 12 from moving up relative to the support member 12.

The illustrated first support surface 54 is provided with a centrallylocated wall that forms opposed first and second abutments 58, 60 thatface in laterally outward directions (that is, in directions horizontaland perpendicular to the longitudinal centerline 28 of the supportmember 18). With a side flange 62, which connects the lower flange 24,engaging the abutment 58, 60 the PV module 12 supported on the firstsupport surface 54 is automatically positioned and aligned to thelongitudinal centerline 28 of the support member 18. The illustratedsecond support surface 56 is provided with a centrally located wall thatforms opposed first and second abutments 64, 66 that face in laterallyoutward direction (that is, in directions horizontal and perpendicularto the longitudinal centerline 28 of the support member 18). With theside flange 62 of the PV module 12 engaging the abutment 64, 66 the PVmodule 12 supported on the second engagement surface 44 is automaticallypositioned and aligned to the longitudinal centerline 28 of the supportmember 18. The hollow side walls 46 form rearward facing abutments 68 attheir rear ends. With the side flange 50 of the PV module 12 engagingthe rear facing abutments 68, the PV module 12 supported on the secondengagement surface 56 is automatically positioned and aligned in theforward/rearward direction relative to the support member 18. Theillustrated abutments 68 are located near the second support surface 56but spaced forward of the second support surface 44.

The illustrated side walls 46 of the support member 18 have cutouts ornotches 70 to hold a ballast 20 in the form of a block positioned on itsside and extending laterally, either across one support member 18 orstraddling two support members 18 (as described in more detailhereinafter). The illustrated notches 70 are located near the forwardwall 42 but are spaced rearwardly from the forward wall 42. Positionedin this manner, the ballast 20 effectively blocks the wind and addsballast weight, without shading any PV module 12 located to the north.An alternative to the illustrated cutouts 70 is to mold a suitablecavity for holding the ballast without cutting out the surfaces of theside walls 46.

The illustrated support members 18 also have holes 72 that accept one ofmany commercially available wire management clips to provide built-inwire management. Suitable wire management cable ties include WIT-40LARand WIT-RRA available from Richco Inc. of Morton Grove, Ill. Analternative is to mold channels into the support member 18 through whichwires from the PV modules 12 can be run.

The bottom surface of the illustrated bottom wall 40 has “tread” orother raised features 74 that increase the traction (or coefficient offriction) between the support member 18 and the flat support surface 14.This increased traction reduces the amount of ballast weight required tokeep the support member 18 from sliding relative to the support surface14 during wind loads. Alternatively and/or additionally, a rubber pad,feet, or the like (such as, for example EPDM) can be provided underneaththe support member 18 to further increase the coefficient of friction.Another alternative is to use a double sided adhesive pad so that thesupport member 18 adheres to the support surface 14. Yet anotheralternative is to use butyl tape or the like under the support member 18when the support surface 14 is a building rooftop so that the butyl willadhere to the rooftop surface once the temperature is high on a hot day,similar to asphalt shingles.

Each of the illustrated support members 18 can carry up to three of theballasts 20 in the form of standard off-the-shelf, commerciallyavailable solid concrete blocks or roof pavers. The illustrated ballastblocks are of the size 4″×8″×16″ and weigh about 31.5 pounds each basedon ASTM Designation C1491-01a. In the illustrated embodiment, two of theballast blocks are stacked and longitudinally extend near a rearward endof the support member 18 and one is positioned on its side and laterallyextends near a forward end of the support member 18. The threeillustrated ballast blocks provide about 94.5 lbs of ballast to thesupport member 18. It is noted that any other suitable quantity,position and orientation of the blocks can alternatively be utilized asdesired for a particular installation. For example, some of theillustrated support members 18 have two ballast blocks that are stackedand longitudinally extend near a forward end of the support member 18.It is noted that any other suitable type, shape, quantity, orientation,weight, and/or size of ballast 20 can alternatively be utilized. Forexample, the ballast 20 can be in the form of water bladders, sandfilled containers, gravel filled containers, or the like. Advantages ofwater over other weight providing materials such as concrete are that itis free, easy to pump the mounting site, safe on the roof membrane orother support surface 14, can be easily drained when decommissioning thePV array 10, and has no impact on the environment. The water bladderwould be sealed to prevent evaporation and undesirable bacteria to causea nuisance. In order to account for expansion and contraction due tofreezing/thawing and temperature changes, airspace could be maintainedabove the water or the bladder could be flexible to expand and contract.

As best shown in FIG. 7, the PV modules 12 can be mounted using the samesupport members 18 to mount the PV modules 12 in the landscapeorientation rather than the portrait orientation. In this portraitorientation, the PV modules 12 are mounted directly to the supportmembers 18 using an attachment system 21 utilizing mounting holes 92provided by the manufacturer of the PV module 12 in the lower flange 24of the PV module 12 (see FIG. 12A). A plastic push rivet is one way tofasten the PV module 12 to the support member 18 but any other suitablefastener, clamp, clip, latch or the like can alternatively be utilized.This alternative landscape orientation can be used in cases where themanufacturer of the PV module 12 requires that the mounting holes 92 ofthe PV module 12 be used or in cases where wind loads require weightexceeding the provisions of the portrait orientation configurationdescribed above.

FIG. 8 illustrates a PV array 10 according to a second embodiment of thepresent invention. This embodiment illustrates that the support members18 can have other suitable forms. The support member 18 of thisembodiment includes a hollow plastic reservoir or tank 76 that can befilled with water for ballast weight. It is noted that the supportmember 18 described hereinabove with regard to the first embodiment ofthe invention could be modified to accomplish this with very littlechange. The void or cavity 48 where the concrete ballast blocks restwould be instead filled by the reservoir 76. The illustrated reservoir76 is formed hollow, filled with water, and sealed closed. A removablecap is provided to seal closed the inlet used to fill the reservoir 76.An air gap within the reservoir 76 allows for water volume changes dueto freezing and thawing. The illustrated PV module 12 is supported atfour locations by identical feet 78. The attachment system 21 securesthe feet 78 to the mounting holes in the PV module's lower flange 24.The attachment system 21 can be any suitable fastener (such as bolt andnuts, plastic push rivets, or the like), clamp, clip, latch, or thelike. It is noted that the tank 76 can naturally create a wind barrierto prevent uplift due to wind blowing below the PV modules 12.

FIGS. 9 to 12 illustrate a PV array 10 according to a third embodimentof the invention. This embodiment also illustrates that the supportmembers 18 can have other suitable forms. The support member 18 of thisembodiment is formed so that the ballast 20, which is in the form of aconcrete block, can lay flat in a transverse direction centrally on thesupport member 18. The support member 18 also does not have the abutmentforming walls so that the lower flange 24 of the PV modules can rest onthe support surfaces 54, 56 and are secured to the support member 18 bythe attachment system 21 in the form of a clamp assembly 80. Theillustrated clamp assembly 80 includes a threaded stud or bolt 82 thatvertically extends through an opening 84 at the support surface 54, 56.A clamping element 86 is secured to the bolt 82 with a nut 88 to form acompression clamp which secures the PV module 12 to the engagementsurface 54, 56 of the support member 18 and the clamping element 86. Theillustrated clamp assembly 80 includes a metal plate 89 in the firm of adisc to secure the stud 82 to the support member 18 but the stud 82 canalternatively be secured in any other suitable manner. The illustratedPV module 12 engages the metal plate 89 and can be conveniently used asa grounding point for the PV Module 12 if desired. Suitable compressionclamp assemblies 80 are S-5-PV clamps which are available from MetalRoof Innovations, Ltd, of Colorado Springs, Colo. It is noted that theattachment system 21 can alternatively be any other suitable fastener(such as bolt and nuts, plastic push rivets, or the like), clamp, clip,latch, or the like. FIG. 12A illustrates an alternative attachmentsystem 21 which includes a bolt and nut 90, 91 with the bolt 90extending through an opening 92 in the lower flange 24 of the PV module12. This attachment system can be particularly useful when themanufacturer of the PV module 12 requires mounting through the flangeopenings 92.

This embodiment also includes a rear wind shield or blocker 94 supportedby the support members 18 at the rear end of the array system 10 inorder to reduce wind load. The illustrated wind shield 94 is held by therearward most ones of the support members 18 and is shaped and spaced adistance from rearward most ones of the photovoltaic modules 12 todeflect wind, blowing from the north, up and over the array ofphotovoltaic modules 12 rather than under the photovoltaic modules 12 inorder to reduce wind load. The illustrated wind shield 94 extends thefull width of the PV array 10 between the outer most lateral edges ofthe PV modules 12 but any other suitable distance can alternatively beutilized and/or more than one wind shield 94 can be utilized to coverthe desired distance. The illustrated wind shield 94 has an arcuateportion forming a concave surface facing rearward and upper and lowerflange portions for securing the wind shield 94 to the support members18. The illustrated upper flange extends in a direction opposed to theconvex surface and the illustrated lower flange extends in the directionof the convex surface. The illustrated wind shield 94 is positioned onthe rear side of the rearward walls 44 of the rearward most supportmembers 18. The illustrated rearward walls 44 are convex to cooperatewith the arcuate portion of the wind shield 94. It is noted that thisshape can be effective defect a portion of the wind even when the windshield 94 is not utilized. The illustrated upper flange engages aportion of the second support surface 56 while the illustrated lowerflange engages a ledge located at the bottom of the rearward wall 44.The wind shield 94 can be held the support members 18 in any suitablemanner. The illustrated wind shield 94 is positioned a distance Drearwardly from the rearward most ones of the photovoltaic modules 12which is at least 1.5 times a maximum height H of the rearward most onesof the photovoltaic modules 12 so that wind is deflected up and over thearray of photovoltaic modules 12. Constructed in this manner, it is notnecessary to close off the entire gap below the rear edge of therearward most PV modules 12. It is noted that the rear wind shield 94can be eliminated if desired.

The wind shield 94 is preferably extruded of a lightweight plasticmaterial but it can alternatively be formed in any other suitable mannerand/or can alternatively comprise any other suitable material. Thelightweight plastic material can be of any suitable type. The windshield 94 is preferably lightweight and non structural, that is, it doesnot significantly increase the structural strength or stiffness of thearray system 10.

The illustrated PV array system 10 also includes a front wind shield 94Awhich is forward facing and positioned at the forward side of the arraysystem 10 to protect against any wind blowing from the south. The frontwind shield 94A is located at the front side of the forward most ones ofthe PV modules 12 and substantially closes the gap under the front edge.The illustrated front wind shield 94 extends the full width of the PVarray 10 between the outer most lateral edges of the PV modules 12 butany other suitable distance can alternatively be utilized and/or morethan one wind shield 94A can be utilized to cover the desired distance.The front side of the rearward walls 44 of the support members 18 aresized and shaped with ledges and a convex portion to cooperate with thefront wind shield 94A in a manner similar to the way the rear side ofthe rearward walls 44 cooperate with the rear wind shield 94. The frontwind shield 94A is preferably constructed identical to the rear windshield 94 so that the advantages of common parts can be utilized. It isnoted that the front wind shield 94A can be eliminated if desired.

The illustrated PV array system 10 further includes intermediate windshields 94B which are rearward facing and positioned between the forwardand rearward sides of the array system 10 to protect against any windblowing from the north at a steep angle or the like. While these windshields 94B may not be effective to deflect all wind up and over the PVmodules 12, they can still reduce the amount of wind that passes underthe PV modules 12. The intermediate wind shields 94B are located atintermediate ones of the support members 18. The illustratedintermediate wind shields 94B extend the full width of the PV array 10between the outer most lateral edges of the PV modules 12 but any othersuitable distance can alternatively be utilized and/or more than onewind shield 94B can be utilized to cover the desired distance. Theillustrated rear sides of forward walls 42 of the support members 18 aresized and shaped with ledges and to cooperate with a pair of theintermediate wind shield 94B one above the other in a manner similar tothe way the rearward walls 44 cooperate with the rear wind shield 94.Configured in this manner the intermediate wind shields 94Bsubstantially close the entire gap below the rearward side of PV modules12 located between the forward and rearward sides of the PV array system10. The intermediate wind shields 94B are preferably constructedidentical to the rear wind shield 94 so that the advantages of commonparts can be utilized. It is noted that the intermediate wind shields94B can be eliminated if desired.

As best shown in FIG. 13, the PV modules 12 can be mounted using thesame support members 18 described-above to mount the PV modules 12 inthe portrait orientation rather than the landscape orientation.

Any of the features or attributes of the above described embodiments andvariations can be used in combination with any of the other features andattributes of the above described embodiments and variations as desired.

From the foregoing disclosure it will be apparent that the mountingsystems according to the present invention provide improved means formounting PV modules to flat rooftops and the like. These attributesprovide the mounting system with important advantages over competitiveproducts on the market today. These advantages include: it isenvironmentally friendly, universal and off-the shelf design, noelectrical grounding is required, rustproof, and no harm the roofmembrane because it does not penetrate the roof in any way.

From the foregoing disclosure and detailed description of certainpreferred embodiments, it will be apparent that various modifications,additions and other alternative embodiments are possible withoutdeparting from the true scope and spirit of the present invention. Theembodiments discussed were chosen and described to provide the bestillustration of the principles of the present invention and itspractical application to thereby enable one of ordinary skill in the artto utilize the invention in various embodiments and with variousmodifications as are suited to the particular use contemplated. All suchmodifications and variations are within the scope of the presentinvention as determined by the appended claims when interpreted inaccordance with the benefit to which they are fairly, legally, andequitably entitled.

1. A mounting system for photovoltaic modules, said mounting systemcomprising, in combination: a plurality of separate support memberssupporting and orienting the photovoltaic modules in an array; whereineach of the photovoltaic modules is supported by at least four of thesupport members; and wherein each of the support members is secured toand supports at least one the photovoltaic modules but is not directlysecured to any of the other support members.
 2. The mounting systemaccording to claim 1, wherein the support members comprise plastic. 3.The mounting system according to claim 2, wherein the support membersare sized and shaped to nest together in a stack for shipping andstorage.
 4. The mounting system according to claim 2, wherein a metalplate is located at an attachment location of the support member for thephotovoltaic modules to ground the photovoltaic modules.
 5. The mountingsystem according to claim 1, wherein the support members are secured tothe photovoltaic modules with clamps.
 6. The mounting system accordingto claim 1, wherein the support members are secured to mounting holes ofthe photovoltaic modules.
 7. The mounting system according to claim 1,wherein the support members are sized and shaped to orient thephotovoltaic modules in a landscape orientation.
 8. The mounting systemaccording to claim 1, wherein the support members are sized and shapedto selectively orient the photovoltaic modules in both a portraitorientation and a landscape orientation.
 9. The mounting systemaccording to claim 1, further including a wind shield at rearward mostones of the support members that is spaced a distance from rearward mostones of the photovoltaic modules and shaped to deflect wind up and overthe array of photovoltaic modules rather than under the photovoltaicmodules to reduce wind load.
 10. The mounting system according to claim9, wherein the distance between the wind shield held and the rearwardmost ones of the photovoltaic modules is at least 1.5 times a maximumheight of the rearward most ones of the photovoltaic modules.
 11. Aphotovoltaic system mounted on a support surface, the system comprising,in combination: a plurality of rectangular-shaped photovoltaic modules;a plurality of separate and spaced-apart support members supporting andorienting the photovoltaic modules in an array on the support surfacewithout penetrating the support surface; wherein each of thephotovoltaic modules is supported by at least four of the supportmembers; and wherein each of the support members is secured to andsupports at least one of the photovoltaic modules but is not directlysecured to any of the other support members.
 12. The photovoltaic systemaccording to claim 11, wherein the support members comprise plastic. 13.The photovoltaic system according to claim 12, wherein the supportmembers are sized and shaped to nest together in a stack for shippingand storage.
 14. The photovoltaic system according to claim 12, whereina metal plate is located at an attachment location of the support memberfor the photovoltaic modules to ground the photovoltaic modules.
 15. Thephotovoltaic system according to claim 11, wherein the support membersare secured to the photovoltaic modules with clamps.
 16. Thephotovoltaic system according to claim 11, wherein the support membersare secured to mounting holes of the photovoltaic modules.
 17. Thephotovoltaic system according to claim 11, wherein the support membersare sized and shaped to orient the photovoltaic modules in a landscapeorientation.
 18. The photovoltaic system according to claim 11, whereinthe support members are sized and shaped to selectively orient thephotovoltaic modules in both a portrait orientation and a landscapeorientation.
 19. A photovoltaic system comprising, in combination: aplurality of rectangular-shaped photovoltaic modules; a plurality ofseparate and spaced-apart support members supporting and orienting thephotovoltaic modules in an array; wherein each of the photovoltaicmodules is supported by at least four of the support members; and a windshield at rearward most ones of the support members that is spaced adistance from rearward most ones of the photovoltaic modules and shapedto deflect wind up and over the array of photovoltaic modules ratherthan under the photovoltaic modules to reduce wind load.
 20. Themounting system according to claim 19, wherein the distance between thewind shield held and the rearward most ones of the photovoltaic modulesis at least 1.5 times a maximum height of the rearward most ones of thephotovoltaic modules.